Axially mating electrical connector



1962 E. c. QUACKENBUSH 3,066,272

AXIALLY MATING ELECTRICAL CONNECTOR File 0 l, 1958 FIG. 7 12 14 12 INVENTOR. Edward Clarke Quackenbush FIG. I

ATTORNEYS United States Patent Ofitice 3,066,272 Patented Nov. 27, 1962 3,665,272 AXIALLY MATHNG ELEtCTERlCAL CQNNECTQB Edward (Ilarke Quacltenhnsh, Hamden, Conn, assignor to The Whitney Blake (Iornpany, New Haven, Conn, a corporation of Qonnecticnt Filed Get. 1, 1958, Ser. No. 764,656 3 (Ilairns. (Q1. 339-6ll) My invention relates to electrical connectors of the axially connecting type and in particular provides a con struction for mounting contact members and conductors in a pro-formed bore in a resilient connector body.

In my copending application, Serial No. 593,863, filed June 26, 1956, now United States Patent No. 2,949,641 issued August 23, 1960, I have described a method of forming connector bodies of the axially mating type in which a resilient connector body is integrally molded within a rigid, open-ended connector housing shell and which can be provided with pre-formed bores suitable for receiving contact members of the axially mating type. My present invention is particularly adapted to providing a construction in such integrally molded connector bodies for securing contact members and conductors in such pro-formed bores. My invention is, however, applicable to any resilient connector body having pro-formed bores whether or not the connector body is integrally molded within a rigid retaining shell.

At the present time there is a demand for a quick disconnect electrical connector suitable for aircraft and missile use which provides a positive seal against moisture and corona effects, which at the same time is absolutely dependable, both mechanically and electrically, and yet which permits ready removal and replacement of contacts and conductors. While there are presently available non-sealed electrical connectors which attain the necessary sealing by adding washers, gaskets or potting or encapsulating compounds, such sealing arrangements, while providing a sealed connector, do not permit removal or replacement of conductors and contacts. Attempts to provide sealed connectors with provision for removing and replacing contacts and conductors have, however, resulted in connectors which are less dependable both mechanically and electrically. For example, while pin and socket contacts in such a connector must be held accurately at pro-determined locations within the connector insulation, most failure have been traced to inadequate provision for positively locking the contacts.

it is a principal object of my present invention to provide an arrangement for positively positioning contacts at pro-determined locations within the connector insulation, i.e. dielectric connector body, while at the same time preserving the sealing requirements of the connector assembly and yet allowing the contacts and conductors to be readily removed and replaced when desired.

It is another important object of my present invention to provide a moisture-proof seating construction for securing contact members and conductors within pre-formed bores in a connector body in a manner preventing extrusion of such contacts and conductors upon the axial mating of such a connector with a correspondingly arranged complementary connector.

It is a further object of my invention to provide a contact and conductor mounting construction that affords individual removal and replacement of contacts and conductors.

it is a still further object of my invention to provide a contact and conductor mounting construction that employs a minimum or" parts.

These and other objects of my invention are essentially obtained by integrally bonding a spring clip in a bore in a resilient dielectric connector body. Such a spring clip is thus a permanent part of the connector body and is aflixed in position in the connector body. One such spring clip is, of course, provided for each contact location. Because the forces tending to dislocate or move contacts within the connector body are always in one direction, the spring clip which I provide is arranged to receive a contact and conductor assembly from the reverse direction and to grip the contact once received such that the contact can be moved only in that reverse direction, thus restraining displacement of the contact and conductor in the first direction by the forces normally encountered in making connection between a pair of mating connectors.

For a more complete understanding of the practical application of my invention, reference is made to the appended drawings, in which:

FIGURE 1 is an elevation of a clip construction according to my invention;

FIGURE 2 is a longitudinal section of a connector plug and receptacle, each includim a clip of the type shown in FlGURE 1;

FIGURE 3 is an elevation of socket and pin contacts suitable for assembly in the receptacle and plug shown in FIGURE 2;

FIGURE 4 is a longitudinal section of the plug and receptacle of FEGURE 2, illustrating these with the contacts of FIGURE 3 inserted in position and connected to suitable conductors; and

FlGURE 5 is a view similar to FIGURE 4 showing the connectors in mating position.

Referring to the drawings, the reference numeral 10 designates a connector receptacle and the reference numeral 2t designates a complementary connector plug for axially mating with receptacle 1 Receptacle it) is provided with a rigid, generally cylindrical shell lit in which a resilient dielectric body 12 is securely positioned. Body 12 preferably is formed by molding it in shell 11' by the method of my aforenoted Patent No. 2,949,641. However, it can be separately molded and subsequently inserted in shell 11 in a conventional manner. Plug 29 is similarly provided with a generally cylindrical shell 21 in which is molded a resilient dielectric body 22.

Each of resilient bodies 12 and 22 is provided with a plurality of parallel, longitudinally disposed bores 13 and 23, respectively, or" which only one of which is shown for the sake of clarity. Each bore 13 includes a terminal end portion 13a, an intermediate portion 13b and a mating end portion 130, which are aligned lengthwise through dielectric connector body 12. Terminal end portion 13a thus opens into the terminal, i.e. non-mating, end 12a of body 12 and mating end portion 13c of bore 13 opens into the mating end face 12b of body 12. Terminal end portion 13a and mating end portion of bore 13 have substantially the same diameter and are interconnected by intermediate portion 135, which tapers from an equal diameter, where it joins the inner end of terminal end portion 13a, to a more restricted cross-section where it joins mating end portion 13c, forming a shoulder 13:! at the inner end of mating end portion 13c of bore 13.

Similarly, each bore 23 includes a terminal end portion 23a, an intermediate portion 23b and a mating end portion 23c, which are aligned lengthwise in dielectric connector body 21). Terminal end portion 23a and mating end portion 23c, respectively, open into the terminal, i.e. non-mating, end 22a and the mating end 2% of dielectric body 22. Portions 23a and 23c are of equal diameter and are interconnected at their inner ends by intermediate portion 23b which tapers from an equal diameter where it joins the inner end of terminal end portion 23a to a more restricted cross-section where it joins the inner end of mating end portion 23c of bore 23, forming a shoulder 23a at the latter junction.

In a conventional manner, connector plug 20 is provided with an integral cylindrical extension 24 at the mating end of shell 21, such that the mating end face 22b of connector body 22 is set back within such cylindrical extension 24. Shell 21, also in a conventional manner, is provided with freely rotatable, internally threaded coupling nut 25, which overlies and is spaced outwardly from cylindrical extension 24 to receive in threaded engagement an externally threaded, cylindrical extension 14 at the mating end of shell ll. of receptacle 1d. Extension 14 is spaced outwardly from the mating end 7.2%; of receptacle connector body 12 permitting cylindrical extension 24 of plug 20 to be received in an axial direction between extension 14 and mating end portion 12b of connector body 12 when plug 20 and receptacle are mated to a position in which the mating ends 12b and 22b of connector bodies 12 and 22 are brought to abutting position in which the mating end portions 13c and 230 of bores 13 and 23 are aligned. Suitably a key 16 and slot 26 are provided in extensions 14 and 24, respectively, in a conventional manner for axial reception upon mating of plug 2th with receptacle It} to assure the proper angular relationship between the connectors.

, Referring more particularly to FIGURE 1, a clip 30, including a straight tubular portion 31, which is slotted lengthwise as indicated by the reference numeral 32, and a pair of integral leaves 33 and 3 in accordance with my present invention is provided in each of bores 13 and 23. More specifically, each clip 36 is made of a relatively stifi metal which preferably is resilient material such as Phosphor-bronze. Leaves 33 and 34 are spaced opposite each other aflixed to one end of tubular portion '31 and extend adjacent to each other from such end of tubular portion 31 such that they can be described as being inclined inwardly toward each other. Thus, at their free ends, leaves 33 and 34 define an end opening of clip 30, which has a more restricted diameter than the opening through tubular portion 31.

Clips 30 are positioned in a bore 13 and 23 (see FIGURE 2) with tubular portions 31 at the inner ends of terminal end portions 13a and 23a, with leaves 33 and 34 lying in intermediate bore portions 13b and 23b and with their end opening of restricted diameter coinciding with the openings of intermediate bore portions 13b and 23b into mating bore portions 130 and 23c. Preferably the interior diameter of tubular portion 31 of each clip 30 is the same as that of the interior diameters of end bore portions 13a, 130, 23a and 230.

Clips 30 must be aflixed within their associated resilient connector bodies 12 and 22, preferably by molding such connector bodies about clips 3! For example, in a typical molding operation a clip 3d will be mounted on the end of a tight-fitting, polished pin having a tapered tip fitting leaves 33 and 34. The molding operation is then carried" out by inserting the pin into the mold space along with a second, flat-tipped, polished pin which is inserted into the mold space from the opposite end to a position abutting the first pin and aligned with it. Thereafter, the dielectric molding compound, such as rubber, isintroduced into the mold space and the molding operation completed by curing and other conventional procedures. After molding When the mold is parted the pins are Withdrawn leaving bores 23, or 23 as the case may be, with a properly inserted clip 3t). Thisoperation can also be carried out in conjunction with the integral molding operation of my aforementioned patent, in which case the pins also serve the function of provid- 1ng surfaces from which the molding material can contract away to accommodate volumetric contraction of the molded body upon curing and cooling. Usually a conventional bonding agent will also be employed on the exterior surfaces of clips ditto assure that they will firmly adhere to the subsequently molded connector body.

Referring more particularly to FIGURE 3 which illustrates suitable contacts 4d and Silfor use in constructing a connector employing receptacle 1t) and plug 2%, socket contact member 4t; will include a terminal end portion 41, a mating end portion 42 and an intermediate portion 4-3, which are aligned lengthwise. Terminal end portion 4-1 is suitably provided with an axial bore 41a in its outer end for receiving the end of an electrical conductor, and mating end portion 42 is also provided with an axial bore 42a in its outer end defining a socket for receiving the pin portion 52 of pin contact member 5% which will be described later. Mating end portion 42 can also be slotted or otherwise constructed in a conventional manner. Generally the exterior diameters of end portions 41 and 42 will be the same and intermediate portion 43 of socket contact 49 will be tapered from its juncture with the innerend of terminal end portion 41 to a more restricted diameter, at which point it enlarges to form a shoulder portion 44 joining tapered portion 43 and mating end 42.

Pin contact 5% similarly is provided with a terminal end portion 51, which can be axially bored at its outer end, as indicated by the reference numeral 53a, for receiving the end of a conductor, and is provided with a pin mating portion 52. Terminal end 51 and pin 52 are joined lengthwise alignment by an intermediate contact portion 53. Pin-portion 52 will generally have a diameter suitable for reception in the axial socket 42a. of the mating end portion 42 of socket contact member 4i), While the terminal end portion 51 of contact 56} will have a largerdiameter suitable for a snug fit in bore 23a. in-

termediate portion 53 tapers from its juncture with terminal end portion 51 to a more restricted diameter and is provided'at its more restricted end with an enlarged flange or shoulder 54 where intermediate portion 53 joins pin portion 52.

Referring more particularly to FIGURE 4, it will be observed that contacts 4t) and 5t) are respectively assembled in receptacle it and plug 26 after first. joining the contacts with conductors for external connection with the electrical circuits to be brought through connector assembly of receptacle lit and plug 2t). Thus, an insulated conductor 6t having its insulation removed at one end fill, is first inserted into the axial bore 41a in the terminal end 41 of socket contact 4t), which is thereupon crimped about bare conductor end 61 to secure mechanical and electrical connection between the conductor and contact. Similarly, a conductor 62, having its insulation stripped from an end 63, is assembled with pin contact by inserting the bare end 63 of conductor 62 into the axial bore Slla in the outer end of terminal portion 51 of contact 50, which is thereupon also crimped to secure conductor 62 and contact 59.

The assembled contact 4d and conductor are pushed into receptacle connector body 12 by inserting mating end portion 42 of contact 44? into terminal end portionv 13a of bore 13 through the non-mating face 12a of body 12 and thereafter forcibly moving contact 44 toward the mating end of body 12. As mating portion 42 of contact 4%) reaches leaves 33 and 34, these are forced apart against the resilient backing of the tapered'intermediate portion 13b of bore'13 until shoulder portion 44 of contact 4d fully enters the inner end of mating end portion of bore 13, at which point leaves 33 and 34 are forced to gether to their normal position by the, release of compression such that they lie against the tapered intermediate portion 43 of contact 44 with their open ends abutting shoulder 44, preventing contact 4% thereafter from moving backward from the mating end of receptacle 1t Similarly, the assembled conductor 62 and pin contact member 59 are forced, pin 52 first, into the terminal end portion 23a of bore 23 of plug 2t), forcing the associated leaves 33 and 3d of clip 36 in plug 2% apart to admit passage of shoulder portion 54 of pin contactfid until shoulder portion 54 lies entirely within the inner end of mating end portion 23c of bore 23, whereupon leaves 33 and 3% are restored to their normalposi-tionby their natural resiliency and the resilient backing of tapered intermediate bore portion 23b, causing the open ends of leaves 33 and 34 to abut 111d lie behind shoulder 54, thereafter preventing movement of pin contact 50 in the reverse direction.

Referring to FIGURE 5, the assembled receptacle and plug are coupled in the conventional manner by bringing them with their mating ends confronting each other in an axial direction to insert pin 52 within socket 42a, to abut mating end faces 12!) and 22b with shell extension 24 received between shell extension 14 and the mating end 12b of connector body 12, with key 16 in slot 26 and with coupling nut rotated threadedly to engage shell extension 14. This axial movement, which ordinarily tends to dislodge contacts, will evidently not do so in connectors employing the construction of my invention because of the abutting action of the open ends of leaves 33 and 34 on the intermediate shoulder portions of their associated contacts. It will be evident, however, that whenever desired, a contact 40 or 50 can be removed and replaced simply by disconnecting the connector parts 10 and 2t), clipping the associated conductor 60 or 62 behind the terminal end of its associated connector body and thereafter pulling the contact and clipped-off portion of conductor forwardly through the mating end face of the connector body. Replacement simply follows the original assembly procedure.

I claim:

1. In an electrical connector of the axially mating type including a resilient dielectric body, means defining a bore through said body opening at one end in one end of said body and opening at the other end in the other end of said body, and a contact member including a mating end portion for axial engagement with a complementary contact member of a complementary connector and a terminal end portion for connection to an external electrical conductor, said contact member being disposed in said bore with said mating end portion adjacent said one end of said bore and with said terminal end portion adjacent said other end of said bore; the improvement which includes a clip including a straight tubular portion, means defining a slot extending lengthwise through said tubular portion, and a plurality of leaves, said leaves being aflixed at and extending adjacent each other from one end of said tubular portion, said leaves being inclined inwardly toward each other to define an end opening therebetween at the ends thereof remote from said tubular portion and said end opening having more restricted transverse dimensions than the opening defined through the center of said tubular portion, said clip being positioned in said bore intermediate the ends thereof with the exterior surfaces of said clip afiixed to the interior walls of said bore, with said tubular portion of said clip facing said other end of said bore and with said restricted end opening in said clip facing said one end of said bore, and said solid bar contact member including an intermediate portion interconnecting said mating end and terminal end portions thereof, said intermediate portion of said contact member tapering inwardly from said terminal end portion to a more restricted cross-section and having a shoulder adjacent said mating end portion facing said tapered portion with said shoulder abutting the ends of said leaves of said clip defining said end opening, with said tapered intermediate portion of said contact member positioned between said inclined leaves of said clip and with said terminal end portion of said contact member received in said tubular portion of said clip.

2. An electrical connector of the axially mating type which includes a resilient dielectric body including means defining a bore through said body, said bore having a mating end portion opening at one end in one end of said body, a terminal end portion opening at one end in the other end of said body and an intermediate portion communicating at one end with the other end of said mating end portion and communicating at the other end with the other end of said terminal end portion, and said mating end, intermediate and terminal end portions of said bore being aligned lengthwise through said body; a clip including a straight tubular portion, means defining a slot extending lengthwise through said tubular portion, and a plurality of leaves, said leaves being afixed at and extending adjacent each other from one end of said tubular portion, said leaves being inclined inwardly toward each other to define an end opening therebetween at the ends thereof remote from said tubular portion, and said end opening having more restricted transverse dimensions than the opening defined through the center of said tubular portion; said clip being positioned in said intermediate portion of said bore with the exterior surfaces of said clip atfixed to the interior walls of said intermediate portion of said bore, with said tubular portion of said clip adjacent said terminal end portion of said bore and with said restricted end opening in said clip adjacent said mating end portion of said bore; and a contact member including a mating end portion for axial engagement with a complementary contact member of a complementary connector, a terminal end portion for connection to an external electrical conductor and an intermediate portion inter-connecting said mating end and terminal end portions, said intermediate portion of said contact member tapering inwardly from said terminal end portion to a more restricted cross-section and having a shoulder adjacent said mating end portion facing said tapered portion; said contact member being disposed in said bore in said body with said shoulder and mating end portion of said contact member lying in said mating end portion of said bore, with said shoulder abutting the ends of said leaves of said clip defining said end opening, with said tapered intermediate portion of said contact member positioned between said inclined leaves of said clip and with said terminal end portion of said contact member received in said tubular portion of said clip and extending toward said terminal end portion of said bore.

3. In an electrical connector of the axially mating type including a resilient dielectric body and means defining a bore through said body opening at one end in one end of said body and opening at the other end in the other end of said body; the improvement which includes a clip including a straight tubular portion, means defining a slot extending lengthwise through said tubular portion, and a plurality of leaves, said leaves being afiixed and extending adjacent each other from one end of said tubular portion, said leaves being inclined inwardly toward each other to define an end opening therebetween at the ends thereof remote from said tubular portion and said end opening having more restricted transverse dimensions than the opening defined through the center of said tubular portion; said clip being positioned in said bore intermediate the ends thereof with the exterior surfaces of said clip afiixed to the interior walls of said bore, with said tubular portion of said clip facing said. other end of said bore and with said restricted end opening in said clip facing said one end of said bore.

References Cited in the file of this patent UNITED STATES PATENTS 1,190,491 Watts et-al July 11, 1916 1,981,460 Miller Nov. 20, 1934 2,411,861 Antony et al. Dec. 3, 1946 2,419,018 Gudie Apr. 15, 1947 2,477,849 Adams Aug. 2, 1949 2,881,406 Arson Apr. 7, 1959 

